Structural Insulated Composite Floor Panel System

ABSTRACT

The invention is a floor that consists of structural insulated composite panels (SICP) made of an expanded polystyrene or polyurethane core and fiberglass reinforced phenolic resin outer skins. The density of the core and the thickness and fiberglass component of the skin as well as the thickness of the panel can be modified depending on the application. The floor panels are supported along the ends by the walls acting as deep beams by a bolt and angle system or by a “Strong Dog” system as well as by an Offset Adjustable Foundation Leg system.

CROSS-REFERENCES TO RELATED APPLICATIONS (IF ANY)

None

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention is directed to a providing support and a tie downmeans for structural insulated composite panel buildings using anStructural Insulated Composite Floor Panel System.

2. Background

There are current techniques for building structural insulated compositepanel buildings that can be used as reusable emergency shelters, homesand structures that are affordable, energy efficient, hurricane andearthquake resistant. These structures will not mold or mildew, arecompletely waterproof and are immune to insects and rodents. They arealso earth friendly, and can be recycled when reaching the end of theirlife cycle

Until now, most structural panels use Oriented Strand Board (OSB) fortheir facings. But there are better materials and connecting systemsthat should be used.

There exists a need for structural insulated composite panel buildings.Especially in areas dealing with natural or manmade issues as they canbe put up quickly and safely provide people with their sheltering needs.There needs to be more improved systems that make it easier, sounder andmore efficient to connect the materials and construct the panelbuildings and to provide support and securing.

There is still room for improvement in the art.

SUMMARY OF THE INVENTION

The current invention deals with current techniques for providingsupport for structural insulated composite panel buildings.

The invention is a Structural Insulated Composite Floor Panel Systemwhich is a light weight floor system that can be rapidly constructedand, if desired, taken apart and re-used. The floor consists ofstructural insulated composite panels (SICP) made of an expandedpolystyrene or polyurethane core and fiberglass reinforced phenolicresin outer skins. The density of the core and the thickness andfiberglass component of the skin as well as the thickness of the panelcan be modified depending on the application.

The floor panels are supported along the ends by the walls acting asdeep beams by a bolt and angle system or by the “Strong Dog” system aswell as by the Offset Adjustable Foundation Leg system. The floor panelsmay be supported at mid span by discrete adjustable supports consistingof plastic or metal bearing pads against the soil and against theunderside of the floor panel. The number, location and size of thesupports can be varied depending on spans and loads. The meeting edgesbetween floor panels have mating slots that are provided with compositeinserts to align the panels and help distribute the load between panels.The size and spacing of the inserts can be varied depending on theapplication.

BRIEF DESCRIPTION OF THE DRAWINGS

Without restricting the full scope of this invention, the preferred formof this invention is illustrated in the following drawings:

FIG. 1 shows the floor panel system;

FIG. 2 shows the double dog and the reverse dog;

FIG. 3 shows the wall panel to floor panel connection;

FIG. 4 shows the wall panel to floor panel in an isometric view;

FIG. 5 shows the telescoping leg assembly on a bearing and hold downpad; and

FIG. 6 shows the assembled offset adjustable leg foundation supportsystem.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS

There are a number of significant design features and improvementsincorporated within the invention.

This invention uses component is U.S. patent application Ser. No.13/975,533 for a Strong Dog Panel Connection System and U.S. patentapplication Ser. No. 14/037,341 for an Offset Adjustable Foundation Legwhich are incorporated by reference.

The invention is a Structural Insulated Composite Floor Panel Systemwhich is a light weight floor system that can be rapidly constructedand, if desired, taken apart and re-used. The floor consists ofstructural insulated composite panels (SICP) made of an expandedpolystyrene or polyurethane core and fiberglass reinforced phenolicresin outer skins. The density of the core and the thickness andfiberglass component of the skin as well as the thickness of the panelcan be modified depending on the application.

The floor panels are supported along the ends by the walls acting asdeep beams by a bolt and angle system 73 or by the “Strong Dog” system55 as well as by the Offset Adjustable Foundation Leg system 10. Thefloor panels 45 may be supported at mid span by discrete adjustablesupports consisting of plastic or metal bearing pads 11 against the soil80 and against the underside of the floor panel 45. The number, locationand size of the supports can be varied depending on spans and loads. Themeeting edges between floor panels have mating slots 20 that areprovided with composite inserts to align the panels and help distributethe load between panels as shown in FIG. 1. The size and spacing of theinserts can be varied depending on the application.

The foundation assemblies are installed in the appropriate locations andadjusted to the correct elevation. The floor panels 45 are placed on thefoundation pads, in order, starting at one edge. The inserts are placedin the panel edges as the panels are installed. The wall panels 40 areinstalled and connected by the Strong dog connection system 55 to thefloor panel. The wall panels can also be connected through a bolt andangle system 73 as shown in FIG. 1

The Strong Dog Panel Connection System connects structural insulatedcomposite roof, wall and floor panels to each other and to othersurfaces such as floors and walls. It is a hidden continuous connectionsystem consisting of fiber reinforced plastic (FRP) holding devicescalled “Strong Dogs” as shown in FIG. 2 and FIG. 4 that engage slots 20in a FRP receiving piece 25 installed in the edge or the face of thepanel 40 or other surface to be attached to as shown in FIGS. 3 and 4.

As shown in FIGS. 2 and 4, double strong dogs 5 are used in strong dogstype one strips 50 for wall connections. The double strong dog 5 hasdouble extensions 1 that extend the same way in parallel from the base2. The reverse strong dog 6 has extensions 1 that extend in oppositiondirections from the base 2. The use of these two types of strong dogsallow for great flexibility in the use of the strong dog strips. Thestrong dogs are wide enough to fit securely into the slots 20 of theslotted channels of the panels. In the preferred embodiment, the strongdogs are made of a strong fiber reinforced plastic.

With a connection between an exterior wall and floor panel the bottomedge of the wall panel 40 has a built in slotted edge channel extendingthe full width of the panel 40 as shown in FIGS. 3 and 4. The corner topedge of the floor panel 45 has a built in slotted channel. The “StrongDog type two” strip 55 is inserted into the slots 30 in the floor panel45 and pulled into the fully engaged position. The wall panel 40 is setdown over the “Strong Dog type two” strip 55 and pushed into a fullengaged position.

An Offset Adjustable Foundation Leg provides support and tie down forstructural insulated composite panel buildings 75 as shown in FIG. 6. Inthe preferred embodiment, it is a telescoping leg 10 made up of outsidesteel or aluminum round or rectangular tube and an inside steel oraluminum round or rectangular tube with the tubes provided with a seriesof holes 7 for through bolting together as shown in FIGS. 5 and 6. Bychanging which holes 7 through which the bolts 8 are attached the heightof the telescoping leg 10 is changed allowing flexibility in its usagewhich is a big advantage if the building 75 needs to be and on uneven orsloping terrain or moved to another location.

The holes are arranged so that the total length of the leg 10 isadjustable to within ¾″ of any height within the range of the device inthe preferred embodiment. The tube making up the bottom of thefoundation leg assembly includes a combination steel 28 and plasticbearing plate 22 that also provides the necessary hold down capacity.The hold down weight is provided by the soil 80 or concrete that isplaced on the bearing/hold down plate 22 as shown in FIG. 5. The size ofthe bearing plate 22 can be varied depending on the downward and upwardload condition. The tube making up the top of the foundation legassembly 10 includes a welded nut-steel plate assembly that receives athreaded steel rod 15 for minor height adjustment. The top of the ¾″threaded steel rod 15 is provided with an attached combination steel andplastic bearing plate. The size of the bearing plate 22 can be varieddepending on the downward load condition. A steel or plastic sidewaysdeflection prevention 50 plate is bolted to the leg assembly 10. Anangle shaped steel or aluminum offset hold down arm 14 is provided toattach the foundation leg assembly 10 to the hold down rod 85 or otherhold down device at the wall 40 of building 75 as shown in FIG. 6.

The foundation assembly 10 is placed in a hole 90 excavated to thecorrect size and depth. The top part of the leg assembly 10 istelescoped out to within ¾″ or less below the correct elevation. A steelor plastic sideways deflection prevention plate 50 is bolted to the legassembly 10. The various adjustment nuts 12 and the hold down arm 14 areinstalled and the threaded rod 16 is turned until the top plate 22 is atthe correct elevation. The nuts 12 are tightened. The hole 90 is filledwith soil 80 or concrete. The hold down arm 14 is attached to thebuilding hold down bolt 85. The hold down bolt 85 goes through the floorpanel 45 and can connect to a wall panel 40.

As to a further discussion of the manner of usage and operation of thepresent invention, the same should be apparent from the abovedescription. Accordingly, no further discussion relating to the mannerof usage and operation will be provided.

With respect to the above description, it is to be realized that theoptimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention. Other types ofpanels can be used besides the SICP panels with the current invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

I claim:
 1. A process comprising; Building a floor using structuralinsulated composite panels (SICP) made of an expanded polystyrene orpolyurethane core and fiberglass reinforced phenolic resin outer skins.2. A process according to claim 1 further comprising; Connecting thefloor panels to wall panels using strong dogs.
 3. A process according toclaim 1 further comprising; Connecting the floor panels to wall panelsusing a bolt and angle system.
 4. A process according to claim 1 furthercomprising; Having a plurality of offset adjustable foundation legssupporting the floor panels.
 5. A process according to claim 4 furthercomprising; Having said offset adjustable foundation leg having bearingplate.
 6. A process according to claim 4 further comprising; Having ahold down weight provided by soil or concrete that is placed on thebearing down plate.
 7. A process according to claim 1 furthercomprising; Having a threaded rod at the top of said leg where said rodis turned for height adjustment.
 8. A process according to claim 7further comprising; Having a bearing plate attached to the top of saidthreaded rod.
 9. A process according to claim 7 further comprising;Having a deflection prevention plate attached to the side of said leg.10. A process according to claim 1 further comprising; Having said anoffset hold down arm attached to the leg assembly which is attached to abuilding.
 11. A process comprising; Building a floor using reusablepanels.
 12. A process according to claim 11 further comprising;Connecting the floor panels to wall panels using strong dogs.
 13. Aprocess according to claim 11 further comprising; Connecting the floorpanels to wall panels using a bolt and angle system.
 14. A processaccording to claim 11 further comprising; Having a plurality of offsetadjustable foundation legs supporting the floor panels.
 15. A processaccording to claim 14 further comprising; Having said offset adjustablefoundation leg having bearing plate and having the leg being comprisedof an outside tube with a series of holes and an inside tube with aseries of holes where bolts are placed in one of more holes when theholes of the inside tube and the outside tube are aligned.
 16. A processaccording to claim 14 further comprising; Having a hold down weightprovided by soil or concrete that is placed on the bearing down plate.17. A process according to claim 11 further comprising; Having athreaded rod at the top of said leg where said rod is turned for heightadjustment.
 18. A process according to claim 17 further comprising;Having a bearing plate attached to the top of said threaded rod.
 19. Aprocess according to claim 17 further comprising; Having a deflectionprevention plate attached to the side of said leg.
 20. A processaccording to claim 11 further comprising; Having said an offset holddown arm attached to the leg assembly which is attached to a building.